Flexible seatback system

ABSTRACT

A vehicle seat suspension system includes first and second side supports defining a seatback structure. An upper component and a lower component are provided, each including at least two outwardly extending flex members. A passenger support includes a periphery operably coupled to distal ends of the flex members. An external peripheral gap is defined between the passenger support and the seatback structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 15/216,047 (now U.S. Pat. No. 9,707,870), filed onJul. 21, 2016, entitled “FLEXIBLE SEATBACK SYSTEM,” which is acontinuation of U.S. patent application Ser. No. 13/749,561 (now U.S.Pat. No. 9,409,504), filed on Jan. 24, 2013, entitled “FLEXIBLE SEATBACKSYSTEM,” the entire disclosures of which are hereby incorporated hereinby reference.

FIELD OF THE INVENTION

The present invention generally relates to a vehicle seat suspensionsystem, and more particularly to a vehicle seating assembly with aflexible seatback suspension system.

BACKGROUND OF THE INVENTION

Vehicle seat assemblies typically include a seatback to support a backof an occupant in an upright sitting position and various reclinedpositions. Similar to other portions of a vehicle seating assembly,seatbacks are commonly designed to support an occupant in the uprightsitting position upon acceleration, change in direction, and collisionof the vehicle. Accordingly, seatbacks are substantially rigid andsizeable in construction.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a vehicle seatsuspension system includes first and second side supports defining aseatback structure. An upper component and a lower component areprovided, each including at least two outwardly extending flex members.A passenger support includes a periphery operably coupled to distal endsof the flex members. An external peripheral gap is defined between thepassenger support and the seatback structure.

According to another aspect of the present invention, a vehicle seatsuspension system includes first and second side supports defining aseatback structure. An upper component and a lower component areprovided, each including at least two outwardly extending flex members.A passenger support includes a periphery operably coupled to distal endsof the flex members. A removable cover stock is disposed over the upperand lower components. An external peripheral gap is defined between thepassenger support and the first and second side supports.

According to yet another aspect of the present invention, a seatsuspension system includes a seatback having first and second sidesupports. A suspension assembly includes outwardly extending flexmembers. A passenger support is operably coupled with the suspensionassembly. An external peripheral gap is defined between the passengersupport and the first and second side supports.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a top perspective view of a vehicle seating assembly in avehicle;

FIG. 2 is a top perspective view of the vehicle seating assembly havinga vehicle seat suspension system;

FIG. 2A is a top perspective view of an additional embodiment of thevehicle seating assembly and vehicle seat suspension system;

FIG. 3 is a side elevational view of the vehicle seating assembly shownin FIG. 2;

FIG. 3A is a side elevational view of the additional embodiment of thevehicle seating assembly shown in FIG. 2A;

FIG. 4 is a top plan view of the vehicle seating assembly shown in FIG.2;

FIG. 4A is a top plan view of the additional embodiment of the vehicleseating assembly shown in FIG. 2A;

FIG. 5 is an exploded top perspective view of a seatback of the vehicleseating assembly shown in FIG. 2, having the suspension system and apassenger support;

FIG. 5A is an exploded top perspective view of a seatback the additionalembodiment of the vehicle seating assembly shown in FIG. 2A, having thesuspension system a passenger support;

FIG. 6 is a front top perspective view of the seatback and thesuspension system shown in FIG. 5;

FIG. 6A is a front top perspective view of the additional embodiment ofthe seatback shown in FIG. 5A;

FIG. 7 is a rear top perspective view of the seatback and the suspensionsystem shown in FIG. 5;

FIG. 8 is an exploded front top perspective view of the suspensionsystem shown in FIG. 5;

FIG. 8A is an exploded front top perspective view of the additionalembodiment of the suspension system shown in FIG. 5A;

FIG. 9 is an exploded rear top perspective view of the suspension systemshown in FIG. 5;

FIG. 10 is a side elevational view of the suspension system shown inFIG. 5, showing an outline of the vehicle seating assembly in dashedlines;

FIG. 10A is a side elevational view of the additional embodiment of thesuspension system shown in FIG. 5A, showing an outline of the vehicleseating assembly in dashed lines;

FIG. 11 is an exploded top perspective view of the passenger supportshown in FIG. 5;

FIG. 12 is a enlarged cutaway view of a periphery of the passengersupport taken at line XII of FIG. 11;

FIG. 13 is a top perspective view of the passenger support shown in FIG.11;

FIG. 14 is a cross-sectional side view of the passenger support taken atline XIV-XIV of FIG. 11, showing the flexible trim being attached to thetrim carrier;

FIG. 15 is a cross-sectional side view of the passenger support taken atline XV-XV of FIG. 13, showing the flexible trim attached to the trimcarrier;

FIG. 16 is a top planar view of the suspension system shown in FIG. 2,having an occupant sitting in the vehicle seating assembly;

FIG. 16A is a top planar view of the additional embodiment of thesuspension system shown in FIG. 2A, having an occupant sitting in thevehicle seating assembly;

FIG. 17 is a top planar view of the suspension system shown in FIG. 16;

FIG. 17A is a top planar view of the additional embodiment of thesuspension system shown in FIG. 16A;

FIG. 18 is a top planar view of the suspension system shown in FIG. 16,having an occupant sitting in the vehicle seating assembly turnedslightly to the right;

FIG. 18A is a top planar view of the additional embodiment of thesuspension system shown in FIG. 16A, having an occupant sitting in thevehicle seating assembly turned slightly to the right;

FIG. 19 is a top planar view of the suspension system shown in FIG. 18;

FIG. 19A is a top planar view of the additional embodiment of thesuspension system shown in FIG. 18A;

FIG. 20 is a top planar view of the suspension system shown in FIG. 18,having an occupant sitting in the vehicle seating assembly turnedconsiderably to the right;

FIG. 20A is a top planar view of the additional embodiment of thesuspension system shown in FIG. 18A, having an occupant sitting in thevehicle seating assembly turned considerably to the right;

FIG. 21 is a top planar view of the suspension system shown in FIG. 20;

FIG. 21A is a top planar view of the additional embodiment of thesuspension system shown in FIG. 20A;

FIG. 22 is a top perspective view of an additional embodiment of avehicle seating assembly;

FIG. 23 is a side elevational cross-sectional view of the suspensionsystem taken at line XVII of FIG. 22;

FIG. 24 is a top plan cross-sectional view of the suspension systemtaken at line XVIII of FIG. 22; and

FIG. 25 is a top perspective view of an additional embodiment of avehicle seating assembly.

DETAILED DESCRIPTION OF THE EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the invention as oriented in FIG. 1. However, itis to be understood that the invention may assume various alternativeorientations, except where expressly specified to the contrary. It isalso to be understood that the specific devices and processesillustrated in the attached drawings, and described in the followingspecification are simply exemplary embodiments of the inventive conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

Referring to FIGS. 1-25, reference numeral 10 generally designates avehicle seat suspension system that has a first side support 12 and asecond side support 14 defining a seatback structure 15. An uppercomponent 16 and a lower component 18 each include at least twooutwardly extending flex members 20. A passenger support 22 includes aperiphery 23 operably coupled to distal ends of the flex members 20. Anexternal peripheral gap 26 is defined between the passenger support 22and the seatback structure 15.

Referring now to FIG. 1, a vehicle seating assembly 24 is positioned indriver's side lactation of a vehicle 25. The vehicle seating assembly 24includes a seat 28 pivotally coupled with a seatback 30. The seat 28 isslidably coupled with a floor 32 of the vehicle 25 about a trackassembly 34. The track assembly 34 is configured to allow the vehicleseating assembly 24 to be adjusted in forward and rearward directionsrelative to the vehicle 25. It is understood that the vehicle seatingassembly 24 may be positioned at various locations throughout thevehicle 25 other than the illustrated position, such as, a passengerside location, a mid-row location, and a rear seat location. It is alsoconceivable that the seat 28 may not include the track assembly 34 andalternatively may be fixedly coupled with the floor 32 of the vehicle25.

As illustrated in FIG. 2, the vehicle seating assembly 24 contains thevehicle seat suspension system 10 of the present disclosure. As such,the seatback 30 of the seating assembly 24 includes the first sidesupport 12 and the second side support 14 that define the seatbackstructure 15. The first and second side supports 12, 14 of the seatbackstructure 15 pivotally couple with a rear portion of the seat 28 andextend upward from the seat 28 to a top portion 36 of the seatback 30.The top portion 36 of the seatback 30 extends between the first andsecond side supports 12, 14. A head restraint 38 is coupled with the topportion 36 of the seatback 30 and is substantially centered between thefirst and second side supports 12, 14. The upper and lower components16, 18 of the suspension system 10 are coupled with and span between thefirst and second side supports 12, 14, such that the suspension system10 is positioned generally between the head restraint 38 and the seat 28to support an occupant's back. It is contemplated that the headrestraint 38 may be integrated with the top portion 36 of the seatback30 or that the head restraint 38 may otherwise not be included on thevehicle seating assembly 24.

The lower component 18 of the suspension system 10, as shown in FIG. 2,includes a flex member 20 extending from each of the first side support12 and the second side support 14 to engage a lower segment 40 of thepassenger support 22. The lower segment 40 is positioned adjacent to theseat 28 and is configured to support a lower back of an occupant.Similarly, the upper component 16 of the suspension system 10 has a pairof flex members 20 extending to engage an upper segment 42 of thepassenger support 22 proximate the first and second side supports 12,14. The flex members 20 of the upper component 16 extend from a centralbody 48 that is pivotably coupled with the first and second sidesupports 12, 14. Accordingly, the upper and lower components 16, 18 eachinclude at least two outwardly extending flex members 20. However, it isconceivable that the upper and lower components 16, 18 may be integratedin a single component spanning the seatback 30 or divided further intoadditional components along the seatback 30.

Still referring to FIG. 2, the lower component 18 also includes a firstside portion 44 and a second side portion 46, such that the first sideportion 44 is distinct and separate from the second side portion 46. Thefirst side portion 44 and the second side portion 46 each include a basesection 47 coupled with the first and second side supports 12, 14,respectively. The first and second side portions 44, 46 also include aflex member 20 that extends from the base section 47 to operably couplewith the lower segment 40 of the passenger support 22. Accordingly, thefirst and second side portions 44, 46 of the lower component 18 are eachindependently coupled with the seatback structure 15 and independentlyextend to operably couple with the lower segment 40 of the passengersupport 22.

The upper component 16 of the suspension system 10, as shown in FIG. 2,includes a pair of flex member 20 extending from both sides of thecentral body 48 to operably couple with the upper segment 42 of thepassenger support 22. The upper segment 42 is positioned between thelower segment 40 of the passenger support 22 and the head restraint 38to support an upper back of an occupant. The central body 48 of theupper component 16 is coupled with a pivot bar 50 that laterally extendsbetween the first and second side supports 12, 14 of the seat structure15. The pivot bar 50 is pivotally coupled to allow the upper component16 to pivot forward and rearward about the pivot bar 50. Further, thepivot bar 50 is operably coupled with a motor 52 to adjustably rotatethe pivot bar 50 and thereby pivot the upper component 16 forward andrearward relative to seat structure 15, as described in more detailbelow.

An additional embodiment of the vehicle seating assembly is illustratedin FIG. 2A and other figures denoted with an “A” suffix, illustratingsimilar components with like reference numerals that also include an “A”suffix. As shown in FIG. 2A, a lower component 18A of the vehiclesuspension system 10A includes three flex members 20A extending from thefirst side support 12A, and three flex members 20A extending from thesecond side support 14A. These flex members 20A have a finger shape thatsimilarly engage the lower segment 40A of the passenger support 22A. Thebase sections 47A of the first and second side portions 44A, 46A spansalong the first and second side supports 12A, 14A, respectively tointerconnect the finger shaped flex members 20A. This additionalembodiment also includes an upper component 16A having two, fingershaped flex members 20A extending from both sides of a central body 48Ato operably couple to an upper segment 42A of the passenger support 20A,proximate the first and second side supports 12A, 14A. In addition theupper and lower segments 42A, 40A of the passenger support 22A includealternative shapes from those disclosed in FIG. 2, to similarly supportthe upper and lower back of an occupant. It is further contemplated thatan alternative embodiment may include more, fewer, or alternativelyshaped flex members extending on either side of an upper component and alower component to engage a passenger support.

As illustrated in FIGS. 3-4, the flex members 20 of the upper and lowercomponents 16, 18 extend forward from the seatback structure 15 to formthe external peripheral gap 26 between the seatback structure 15 and thepassenger support 22. The external peripheral gap 26 may be reduced insize proximate a force acting on the passenger support 22, compressingone or more flex members 20 supporting the passenger support 22. Assuch, the upper component 16 and the lower component 18 areindependently flexible under the weight of an occupant, as described inmore detail below. As shown in FIG. 4, the flex members 20 of the upperand lower components 16, 18 also extend forward and laterally outward tooperably couple with angled side bolsters 54 of the passenger support22. The angled side bolsters 54 are configured to prevent lateralmovement of a back of an occupant relative to the passenger support 22,such as lateral movement of an occupant's back when experiencing acentrifugal force from turning the vehicle 25.

Further, as shown in FIGS. 3A-4A, the additional embodiment of theseating assembly 24A has alternatively configured flex members 20A thatsimilarly form an external peripheral gap 26A between the passengersupport 22A and the seatback structure 15A. Also, the additionalembodiment, as illustrated in FIG. 4A, includes angled side bolsters 54Aof the passenger support 22A. However, it is conceivable that theseatback 30A may be configured without angled side bolsters 54A. It isalso contemplated that the external peripheral gap 26A may be concealedby a cover stock material, a flexible shroud, or other conceivablebarriers to visually conceal and/or to conceal from insertion ofobjects.

The seatback structure 15, as shown in FIG. 5, includes a metal frame 56and a plastic trim shell 58 configured to substantially enclose themetal frame 56. The metal frame 56 has a first side member 60 and asecond side member 62 extending upward from a recliner bracket 64 thatpivotally couples with the seat 28 (FIG. 2). The first and second sidemembers 60, 62 are substantially parallel with each other and curveupward and rearward from the recliner bracket 64 to provide a curvedshape that is substantially similar to an occupant's spinal column.Further, the side members 60, 62 are more robust proximate the reclinerbracket 64 and taper as they extend upward to couple with a top member66 that extends orthogonally between the first and second side members60, 62. Accordingly, the first and second side supports 12, 14 of theseatback structure 15 include the first and second side members 60, 62,respectively, and the top portion 36 of the seatback structure 15includes the top member 66 of the metal frame 56. The top member 66includes connectors 68 for securing the head restraint 38 at a centralportion of the top member 66 centrally between the first and second sidemembers 60, 62. The connectors 68 include upward protruding tabsconfigured to couple with the head restraint 38.

As also shown in FIG. 5, plastic trim shell 58 includes a back trimpanel 72 and a front trim panel 74. The back trim panel 72 couples withthe metal frame 56 to substantially enclose the rear portion of the seatstructure 15. Similarly, the front trim panel 74 has an upper piece 75and a lower piece 76 that each couple with the metal frame 56 to enclosethe front portion of the seat structure 15. The lower piece 76 of thefront trim panel 70 couples with the flex members 20 of the lowercomponent 18, and as such, supports the lower segment 40 of thepassenger support 22. The upper piece 75 of the front trim panel 70couples with the lower piece 76 at a central area of the seatback 30.The upper pieces 75 also includes a mounting cutaway 74 for receivingthe head restraint 38 that extends there through to couple with the topmember 66 of the metal frame 56. Further, the upper component 16 ispositioned forward the upper piece, as explained in more detail below.The front trim panel 70 and the back trim panel 72 also engage the metalframe 56 proximate the top member 66, the first side member 60, and thesecond side member 62, substantially enclosing the edge portion of themetal frame 56. The shell 58 is typically molded with a polymer materialand the frame 56 is constructed substantially of steel, aluminum, oranother substantially rigid metal. It is conceivable that alternativematerials or forming methods may be used for the shell 58 and the frame56. In addition, the shell 58, or portions thereof, may conceivably beintegrated with the frame 56.

Still referring to FIG. 5, the upper and lower components 16, 18 of thesuspension system 10 are configured to operably couple with thepassenger support 22. More specifically, the flex members 20 on theupper and lower components 16, 18 extend forward to engage the upper andlower segments 42, 40 of the passenger support 22. The upper and lowersegments 42, 40 include a trim carrier 78, a cushion 80, and a coverstock 82. The flex members 20 operably couple to the trim carrier 78 ina snap-fit and friction-fit arrangement. The cushion 80 is disposedbetween the trim carrier 78 and the cover stock 82, as described in moredetail below. It is conceivable that the passenger support 22 mayinclude more or fewer layers between the cover stock 82 and the trimcarrier 78. Further, it is conceivable that the upper and lower segments42, 40 of the passenger support 22 may be an integral piece with eachother and/or with the upper and lower components 16, 18 of thesuspension system 10

In the additional embodiment illustrated in FIG. 5A, the front trimpanel 70A is comprised of one piece having an inverted U-shape that doesnot include a portion spanning between a central portion of the firstand second side members 60A, 62A of the metal frame 56A. Accordingly, inthe embodiment shown in FIG. 5A, flex members 20A of the lower component18A extend around the front trim panel 70A to directly coupled with thefirst and second side members 60A, 62A of the metal frame 56A. Inaddition, the connectors 68A that are configured to couple with the headrestraint 38A include fastener apertures. It is conceivable that avariety of connectors 68A may be used to couple the head restraint 38Awith the seatback 30A.

Referring now to FIGS. 6-7, the first and second side portions 44, 46,of the lower component 18 each include a flex member 20 that extendsfrom the elongated base portion 47. The elongated base portions 47 eachinclude three apertures arranged longitudinally and in alignment withthe first and second side supports 12, 14 for fastening the first andsecond side portions 44, 46 of the lower component 18 to the lower piece76 of the front trim panel 70. The flex members 20 of the lowercomponent 18 extend forward and outward from the base portions 47 tocreate the external peripheral gap 26. The pivot bar 50 spans betweenand pivotally couples with the first and second side supports 12, 14,generally above the lower component 18. More specifically, the pivot bar50 extends through holes 83 in the lower piece 76 of the front trimpanel 70 to rotatably couple with a rearward protruding bracket 85 fromthe front trim panel 70. A support bar 51 extends in substantiallyparallel alignment rearward the pivot bar 50 and couples with the endportions of the pivot bar 50. The pivot bar 50 is operably coupled withthe motor 52 to pivotally adjust the pivot bar 50, which also rotatesthe support bar 51. An extension bracket 84 fixedly couples andprotrudes upward from an intermediate portion of the support bar 51 to alocation forward the upper piece 75 of the front trim panel 70. Theextension bracket 84 supports the upper component 16 of the suspensionsystem 10. As such, pivotally adjusting the pivot bar 50 in turn adjuststhe upper component 16 forward and rearward to support the upper back ofan occupant.

In the additional embodiment shown in FIG. 7A, the elongated baseportions 47A of the lower component 18A directly engage an interior faceof the first and second side members 60A, 62A of the metal frame 56A.The flex members 20A similarly extend forward and curve outward frombase portions 47A to create the peripheral gap 26A. In this embodiment,the pivot bar 50 rotatably couples with and extends between the baseportions 47A. An extension bracket 84A fixedly couples and protrudesupward from an intermediate portion of the pivot bar 50A to support andpivotally adjust the upper component 16A of the suspension system 10. Itis conceivable that the upper component 16A may be coupled with thefirst and second side supports 12A, 14A, of the seatback structure 15Awithout a pivot bar 50A or other pivoting connection.

As illustrated in FIGS. 8-9, the extension bracket 84 couples with thecentral body 48 of the upper component 16. The central body 48 of theupper component 16 is substantially rectangular shaped and includesstructural flanges 96 between the extension bracket 84 and the flexmembers 20 to provide structural support to central body 48. The flexmembers 20 on the upper component 16 fan upward and outward fromstructural flanges 96 of the central body 48 to provide support to theupper back and shoulders of an occupant, such that weight of an occupantagainst the upper segment 42 of the passenger support 22 (FIG. 5) causesthe flex members 20 to bend rearward proximate the occupants appliedweight. However, the structural flanges 96 and other portion of thecentral body 48 are substantially rigid relative to the flex members 20,such that the bending movement is directed proximate the flex members20.

The additional embodiment, as illustrated in FIG. 8A, includes a fulcrum98A disposed at the middle portion of the central body 48A of the uppercomponent 16A and extends between structural flanges 96A disposed on atop edge and a bottom edge of the central body 48. The fulcrum 98A isadapted to engage the extension bracket 84A that protrudes upward fromthe pivot bar 50A to allow the central body 48A to pivot laterally aboutthe fulcrum 98A. Accordingly, in addition to the rearward bendingmovement of the flex members 20A of the upper component 16A under theweight of an occupant, the upper component 16A also pivots laterallyabout the fulcrum 98 to accommodate movement of an occupant's upper backand shoulders. Further, the additional embodiment includes a keyed end90A on the pivot bar 50A to engage a slot 88A in the base portion 47A ofthe lower component 18A. The pivot bar 50A also has a circular end 92Ato engage a rotation aperture 86A in the base portion 47A of theopposing side of the lower component 18A. The keyed end 90A of the pivotbar 50A allows the pivot bar 50A to be installed after the first andsecond side portions 44A, 46A are coupled with the metal frame 56A. Insuch an additional embodiment, the elongated base portions 47A have asubstantially rectangular prism shape.

As also shown on the embodiment illustrated in FIG. 8A, the flex members20A have distal ends 94A that each include a paddle portion 100A toengage the passenger support 22 (FIG. 5A). The paddle portions 100A havea protrusion 102A to engage the passenger support 22A in a snap-fitarrangement. As such, the flex members 20A of this embodiment areconfigured to bend between the paddle portions 100A and the baseportions 47A, allowing the flex members 20A to elastically deform underthe weight of an occupant. It is conceivable that the flex members 20Amay be alternatively shaped to provide greater or less rigidity to thepassenger support 22A. In addition, it is contemplated that the fingerportions of the flex members 20A may be individually detachable from thebase portion 47A of the lower component 18A or the central body 48A ofthe upper component 16A to allow for replacement and/or customizedrigidity to the passenger support 22A proximate the detachable fingerportion.

As illustrated in FIG. 10, the upper component 16 is pivotable forwardand rearward about the pivot bar 50. The motor 52 is operably coupledwith the pivot bar 50 to rotatably adjust support bar 51 and the uppersegment 42 of the passenger support 22 forward and rearward relative tothe lower segment 40. A linkage 104 couples the motor 52 with an endportion of the pivot bar 50. The linkage 104 may conceivably include adirect gear connection between motor 52 and the pivot bar 50. The uppercomponent 16 is pivotal between a forward position 112, a rearwardposition 114, and various intermediate positions 116 there between. Theupper component 16 in the rearward position 114 is defined by the uppersegment 42 of the passenger support 22 substantially aligned with theseatback structure 15, as also shown in FIGS. 1-4. As the uppercomponent 16 moves to the intermediate positions 116 and further to theforward position 112, the upper segment 42 of the passenger support 22tilts forward to provide additional support to the upper back of anoccupant. Accordingly, the external peripheral gap 26 expands proximatethe upper component 16 as the upper segment 42 of the passenger support22 pivots forward to the forward position 112. It is contemplated thatthe seating assembly 24 may be configured to optionally pivot the uppercomponent 16 from the rearward position 114 to the intermediatepositions 116 and further to forward position 112 simultaneously as theseatback 30 reclines from an upright position, as illustrated in FIG.10, to a reclined position relative to the seat 28, as generallyunderstood in the art.

As shown in FIG. 10A, the additional embodiment includes linkageassembly 104A coupling the keyed end 90A of the pivot bar 50A with themotor 52A to allow the upper segment 40A of the passenger support 22A topivot about the pivot bar 50A. Such a linkage assembly 104A includes atop link 106A that is fixedly coupled with the pivot bar 50A and thatextends down and forward from the pivot bar 50A. An L-shaped bottom link108A pivotally couples with the top link 106A at an upper end of thebottom link 108A and pivotably couples with a pin 110A at a lower end ofthe bottom link 108A. The pin 110A is threaded to engage a worm gear113A operably coupled with the motor 52A. The motor 52A operates todrive the pin 110A up or down based upon the rotational direction of themotor 52A. It is conceivable that the motor 52A may be replaced with amanually rotatable knob to cause the upper component 16A to pivot aboutthe pivot bar 50A. Further, it is conceivable that various linkagealternative arrangements or other means, such as a Bowden cable, may beused to rotate the pivot bar 50A and pivot the upper component 16A.

Referring to FIG. 11, the upper and lower segments 42, 40 of thepassenger support 22 include the trim carrier 78, the cushion 80, andthe cover stock 82. The trim carrier 78 has a substantiallypolymer-based structure that is formed to the contour of an occupant'sback and is flexible to elastically deform somewhat under the weight ofan occupant in conjunction with other portions of the suspension system10, as provided in more detail below. Further, the passenger support 22has the periphery 23 that operably couples to the flex members 20. Morespecifically, the periphery 23 of trim carrier 78 of the passengersupport 22, as shown in FIG. 12, includes an outer edge 118 and aplurality of connection holes 120. The plurality of connection holes 120are positioned to engage the protrusions 102 on the flex members 20(FIG. 8) in a snap-fit arrangement. The trim carrier 78 is shown havingtwo substantially solid molded plastic panels, one for each of the upperand lower segments 42, 40 of the passenger support. However, it isconceivable that the upper and lower segments 42, 40 may be a singlepiece with a living hinge disposed there between to allow for pivotalmovement of the upper component 16. The trim carrier 78 also includesopenings formed in a shape and pattern to increase the flexibility andventilation of the passenger support 22. It is conceivable that theopenings may be formed in an alternative pattern and/or a series ofventilations holes dispersed uniformly or intermittently over portionsof the trim carrier 78 for the desired flexibility and ventilation ofthe passenger support 22.

The cushion 80 of the upper segment 42 of the passenger support, asshown in FIG. 11, has an inner portion 121 and two outer portions 122laterally positioned on the sides of the inner portion 121 proximate theflex members 20 of the upper component 16 (FIG. 5). The inner and outerportions 121, 122 are disposed over the trim carrier 80 of the uppersegment 43. Similarly, the cushion 80 of the lower segment 40 has acentral portion 124 and two side portions 126 that are positionedlaterally adjacent the central portion 124 and engage the trim carrier78 of the lower segment 40. The outer edge 118 of the trim carrier 78,as shown in FIG. 12, protrudes forward from an engagement surface thathas the plurality of connection holes 120 and that engages the cushion80. The outer edge 118 laterally retains the outer portions 122 and theside portions 126 of the cushion 80. The outer portions 122 and the sideportions 126 of the cushion 80 engage portions of the trim carrier 78that flair forward to create the angled side bolsters 54 (FIG. 4), asdescribed above. The cushion 80 includes a matrix of woven fibers thathave open areas to allow ventilation. However, it is also conceivablethat the cushion 80 may include various alternative flexible andbreathable materials, such as polyurethane foam or other conceivablematerials.

As illustrated in FIGS. 13-15, the cover stock 82 of the passengersupport 22 includes a securing rim 130 disposed on an edge portion 128of the cover stock 82 that secures the cover stock 82 to the passengersupport 22. The cover stock 82 covers the cushion 78 and wraps aroundthe outer edge 118 of the trim carrier 78 to engage a groove 134 formedin the rear side of the exterior edge 118, as shown in FIG. 14. Morespecifically, the securing rim 130 includes a retention surface 132 thatis configured to engage a lip 136 formed within the groove 134. Theretention surface is substantially orthogonal to the cover stock 82 andthe lip 136 is, similarly, orthogonal to the groove 134. Accordingly,upon insertion of the securing rim 130 of the cover stock 82 into thegroove 134, as shown in FIG. 15, the securing rim 130 slides over thelip 136 and the retention edge 136 of the securing rim engages the lip136, engaging the cover stock 82 with the trim carrier 78. The coverstock 82 also holds the cushion 80 against the trim carrier 78. Thecover stock 82 may be removed by disengaging the securing rim 130without disassembling other portions of the seating assembly, such thatreplacement of the cover stock 82 and/or cushion 70 is improved. Thesecuring rim 130 is coupled to the cover stock 82 with a plurality offasteners 140, shown as stitching. The fasteners 140 may conceivablyinclude staples, rivets, and adhesive, among other conceivablefasteners. It is also conceived that the securing rim 130 may beextruded over the edge portion 128 of the cover stock 82, among otherattachment means other than fasteners 140. It is contemplated that thecover stock 82 may also extends over the external peripheral gap 26(FIG. 3), coupling with the seatback structure 15 to conceal theexternal peripheral gap 26. The cover stock 28 may conceivably becomprised of fabric, leather, elastic, or any other upholsterymaterials.

Referring now to FIGS. 16-17, the suspension system 10 is shown with anoccupant in an upright sitting position with the occupant's back restingagainst the passenger support 22 of the seatback 30. In such a position,the occupant is substantially distributing weight evenly to the flexmembers 20 on both sides of the suspension system 10. Accordingly, theflex members 20 of the upper component 16 and of the first and secondportions 44, 46 of the lower component 18 are equally deformed rearwardto absorb the weight of the occupant. As such, the external peripheralgap 26 is substantially equal on either side of the passenger support22. As shown in FIGS. 16A-17A, the upper component 16A of thealternative embodiment is also not laterally pivoted about the fulcrum98A, similarly maintaining the peripheral gap 26A at a substantiallyequal size on either side of the passenger support 22A.

As shown in FIGS. 18-19, the occupant has turned slightly to the right,adjusting the occupant's weight distribution on the suspension system10. As such, the flex member 20 on the right side of the upper component16 has flexed rearward, following the movement of the occupant'sshoulders and upper back. The flex member 20 extending from the secondside portion 46 of the lower component 18 also reacts to the occupant'sillustrated movement by elastically deforming slightly rearward. Theupper component is configured to allow for greater movement anddeformation at the flex members 20 to accommodate to greater range ofpotential movement in an occupant's shoulder area than the occupant'slower back area. Accordingly, the external peripheral gap 26 is slightlyreduced proximate the second side portion 46 of the lower component 18and reduce relative more proximate the right side flex member 20 of theupper component 16.

In response to the occupant's movement, the additional embodiment, asshown in FIGS. 18A-19A, also includes the upper component 16A pivotedlaterally to the right about the fulcrum 98A. The lateral pivotingmovement of the upper component forces the flex members 20A on the rightto move rearward and forces the flex members 20A to the left to moveforward, following the movement of the occupant's shoulders and upperback. Accordingly, the external peripheral gap 26A proximate the uppercomponent 16A is reduced on the right side of the passenger support 22Aand slightly increased on the left side of the passenger support 22A.

As illustrated in FIGS. 20-21, the occupant has turned more to the rightfrom the position shown in FIGS. 18-19, thereby further adjusting theoccupant's weight distribution to the suspension system 10. In thisposition, the flex member 20 of the upper component 16 on the occupant'sright side has elastically deformed further rearward to provide someresistance to the occupant's turning motion. The elastic deformation ofthe upper component 16, therefore, provides support to the occupant'supper back that adapts to movement and position changes of the occupant.Additional deflection also occurs to the flex member 20 extending fromthe second side portion 46 of the lower component 18 by furtherelastically deforming rearward, thereby also providing adaptable supportto the occupants' lower back. As such, the external peripheral gap 26 isfurther reduced on the right side of the passenger support 22. It iscontemplated that movement of the occupant back to the forward facingposition shown in FIGS. 16-17 will result in the flex members 20 toelastically regain a substantially similar orientation and therebyregain the peripheral gap 26 with a substantially equal size on eitherside of the passenger support 22. Further, it is contemplated thatmovement of the occupant to the left that corresponds with the movementshown in FIGS. 18-21, will result in substantially mirrored deformationof the flex members on the left side of the suspension system 10.

With reference again to the additional embodiment, as shown in FIGS.20A-21A, the occupant is similarly turned more to the right, such thatthe upper component 16A has continued to pivot laterally to the rightabout the fulcrum 98A. The pivotal movement about the fulcrum 98A againforces the flex members 20A on the right to move further rearward andthe flex members 20A to the left to move further forward, in generalalignment with the occupant's shoulders and upper back. The flex members20A of the upper component 16A on the occupant's right side alsoelastically deform rearward to provide added resistance to theoccupant's turning motion and adaptable support to the occupant's upperback.

Another alternative embodiment of the suspension system 10 is shown inFIGS. 22-24, similarly including an upper component 144 and a lowercomponent 146. The upper component 144 has a first central body 148 thisis pivotably coupled with a first cross bracket 150 spanning between thefirst and second side members 60, 62 of the metal frame 56. As such, theupper component 144 is configured to pivot laterally about the pivotalconnection between the first central body 148 and the first crossbracket 150. The first central body 148 similarly includes two flexmembers 20 extending forward and laterally from both sides of the firstcentral body 148 to engage a passenger support, such that the uppercomponent 144 is configured to pivot and elastically deform to provideresistance to the occupant's turning motion and adaptable support to theoccupant's upper back. However, the upper component 144 of thisembodiment does not pivot forward relative to the lower component 146.

The lower component 146 of this alternative embodiment, as shown inFIGS. 22-24, includes a second cross bracket 152 that spans between thefirst and second side members 60, 62 of the metal frame 56. The lowercomponent 146 also includes a second central body 154 that is pivotablycoupled with the second cross bracket 152. The second central body 154includes an upper portion 156 and a lower portion 158, which each havetwo flex members 20 extending forward and laterally outward from boththe central body 154 to engage a passenger support. The flex members 20of the upper and lower portions 156, 158 of the lower component 146 thatare adjacent to each other integrally join at the distal ends thereof.As such, the lower component 146 engages a passenger support 22 at sixdistal ends of the flex members 20. The second cross bracket 152includes a bulging portion 160 that is configured to fit between theupper and lower portions 156, 158 of the second central body 154, suchthat a pivot pin 162 extends though the upper portion 156, the bulgingportion 160, and the lower portion 158 to provide a pivotal connection.The lower component 146, therefore, may pivot laterally about the pivotpin 162, similar to the upper component 16, to provide pivoting andelastically deforming resistance to the occupant's entire back.

As shown in FIG. 24, the second cross bracket 152 engages a rear flange164 of the metal frame 56 that extends laterally from an interior face165 of the metal frame 56. A bolt 166 extends through a first hole 168in the rear flange 164 and then through a second hole 170 in the secondcross bracket 152 to attach the second cross bracket 152 to the metalframe 56. A bushing 172 is disposed between the second cross bracket 152and the metal frame 56 to increase effectiveness of the suspensionsystem and reduce wear between the metal frame 56 and second crossbracket 152. The first cross bracket 150 similarly engages the metalframe 56 with a bushing 172 and bolt 166.

Yet another alternative embodiment of the suspension system 10 is shownin FIG. 25, similarly including an upper component 174 and a lowercomponent 176. In this embodiment, the upper and lower components 174,176 span between the first and second side members 60, 62 of the metalframe 56 in more of a linear configuration. Further, the lower component176 similarly includes a pivot pin 178 to allow lateral pivotingmovement, in addition to the elastic deformation of the flex members 20.It this embodiment the upper component 174 does not pivot laterally, andalternatively adapts to any shifts in an occupant's weight or positionby elastic deformation of the flex members 20.

Ultimately, the flex members 20 shown in the various embodiments providelocalized deflection for a passenger that corresponds with thepassenger's shifts in weight, shoulder movements, and other commonpassenger movements that may occur during operation of the vehicle 25 orother occurrences when the passenger is seated in the seating assembly24. The localized deflection of the flex members 20 may be enhanced orcustomized for additional compliance to a passenger's size by using flexmembers 20 with varied thickness, shaped, and overall construction, suchas removing and replacing the finger shaped flex members 20A of theadditional embodiment, as shown in the A suffixed figures, with morerigid or more resilient flex members 20A. The localized deflection andoverall compliance provided by the flex members 20, in conjunction withthe entire suspension system 10, enhances the ride and comfortexperienced by a passenger and provides the desired supportcharacteristics.

It will be understood by one having ordinary skill in the art thatconstruction of the described invention and other components is notlimited to any specific material. Other exemplary embodiments of theinvention disclosed herein may be formed from a wide variety ofmaterials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the invention as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present invention. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present invention, and further it is to beunderstood that such concepts are intended to be covered by thefollowing claims unless these claims by their language expressly stateotherwise.

What is claimed is:
 1. A vehicle seat suspension system comprising:first and second side supports defining a seatback structure rotatablycoupled with a seat; an upper component rotatably coupled with theseatback structure and including at least two outwardly extending flexmembers having distal ends with forwardly-extending connection features;and an upper passenger support having a periphery operably coupled tothe forwardly-extending connection features.
 2. The vehicle seatsuspension system of claim 1, wherein the upper component is operablycoupled to an upper segment of the passenger support and is configuredto pivot laterally relative to the seatback structure.
 3. The vehicleseat suspension system of claim 2, wherein the upper component isoperably coupled with a motor that translates the upper segment betweenforward and rearward positions.
 4. The vehicle seat suspension system ofclaim 1, further comprising: a lower component having a first sideportion and a second side portion, and wherein the first side portion isdistinct and separate from the second side portion.
 5. The vehicle seatsuspension system of claim 4, wherein the upper passenger supportincludes a trim carrier, a cushion, and a cover stock.
 6. The vehicleseat suspension system of claim 5, wherein the lower component includesa trim carrier, a cushion, and a cover stock, which are distinct fromthe trim carrier, the cushion, and the cover stock of the uppercomponent.
 7. The vehicle seat suspension system of claim 1, wherein aperiphery of the upper passenger support snap-fit engages theforwardly-extending connection features.
 8. A vehicle seat suspensionsystem comprising: first and second side supports defining a seatbackstructure; an upper component and a lower component, each including atleast two outwardly extending flex members; and a passenger supporthaving a periphery operably coupled to distal ends of the flex membersand an outer edge removably coupled with a cover stock.
 9. The vehicleseat suspension system of claim 8, wherein the cover stock includes asecuring rim that secures the cover stock to the passenger support. 10.The vehicle seat suspension system of claim 8, wherein the uppercomponent includes a first flex member, a second flex member, and acentral body disposed therebetween.
 11. The vehicle seat suspensionsystem of claim 8, wherein the upper component is operably coupled to anupper segment of the passenger support operable between a forwardposition and a rearward position.
 12. The vehicle seat suspension systemof claim 11, wherein the upper segment is operably coupled with a motorthat translates the upper segment between the forward and rearwardpositions.
 13. The vehicle seat suspension system of claim 8, whereinthe lower component includes a first side portion that is distinct andseparate from a second side portion.
 14. The vehicle seat suspensionsystem of claim 11, wherein the upper component is operably coupled tothe upper segment of the passenger support and is configured to pivotlaterally relative to the seatback structure.
 15. A seat suspensionsystem comprising: a seatback including first and second side supports;a suspension assembly rotatable about a horizontal pivot axis and havingoutwardly extending flex members; and a passenger support operablycoupled with the suspension assembly, wherein the passenger support isalso laterally pivotal.
 16. The seat suspension system of claim 15,further comprising: an upper component and a lower component, eachincluding at least two outwardly extending flex members, and wherein theupper component includes a first flex member, a second flex member, anda central body disposed therebetween.
 17. The seat suspension system ofclaim 16, wherein the upper component is operably coupled to an uppersegment of the passenger support translatable between a forward positionand a rearward position, and wherein the lower component includes afirst side portion and a second side portion, wherein the first sideportion is distinct and separate from the second side portion.
 18. Theseat suspension system of claim 17, wherein the upper component isoperably coupled with a motor that translates the upper segment betweenthe forward and rearward positions, and wherein the upper segment ispivotal about a pivot bar, wherein the pivot bar is rotatably coupled tothe first side portion and the second side portion, each of the firstand second side portions including a base portion with at least twooutwardly extending flex members.
 19. The seat suspension system ofclaim 17, wherein the first side portion is connected to the first sidesupport by a first base portion and the second side portion is connectedto the second side support by a second base portion.
 20. The seatsuspension system of claim 16, further comprising: a cover stockdisposed over the upper and lower components, wherein the cover stockincludes a securing rim on an edge portion of the cover stock thatsecures the cover stock to the passenger support.